Systems and methods for thermal management in inductors

Abstract

A thermal management includes an inductor, a housing in thermal communication with the inductor, the housing defining a wall, and a conductor. The conductor has a greater heat transfer rate than the wall and is positioned within a groove and / or an aperture formed in the wall. The conductor is configured to transfer heat through the wall more efficiently than if the conductor were not present. A method of manufacturing a thermal management system includes forming a housing by additive manufacturing. The housing defines a wall having at least one of a groove and an aperture defined therein. The method includes positioning a conductor in at least one of the groove and the aperture. The conductor has a greater heat transfer rate than the wall. The method includes positioning an inductor into thermal communication with the housing.

Description

BACKGROUND1. Field[0001]The present disclosure relates to inductors, and more particularly to thermal management in inductor assemblies.2. Description of Related Art[0002]Inductors are important components in power electronics circuits. A variety of systems are used to create efficient thermal management in order to meet inductance requirements. The inductor generally includes a core and a wire winding wrapped or coiled around the core. The inductor is generally positioned within a metal housing. The wire winding needs to be spaced apart from the metal housing, the space between the winding and the metal housing is typically filled with potting material. The core material, potting material, and wire insulations for the windings generally have temperature limits. These temperature limits and other thermal requirements require efficient heat transfer from the heat-generating components (the core and wire winding), and / or a coolant used (which can sometimes be at high temperature, e.g....

AI Technical Summary

Benefits of technology

This patent relates to a thermal management system that includes a housing with a groove and an aperture for a conductor to transfer heat. The conductor is a heat pipe with a greater heat transfer rate than the wall of the housing. The housing can be made using additive manufacturing. The technical effects of this system include efficient heat transfer, improved heat distribution, and improved manufacturing flexibility.

Problems solved by technology

Generally, heat is transferred to the heat sink using the potting material which generates large gradient between the heat generating components and heat sink due to lower thermal conductivity of the potting material.

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